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© ABB Lummus Global - 1 - 10.08.01 Alternate technology options for processing refinery residues Dan Cooperberg ABB Lummus Global Gasification Technology Conference October 8, 2001

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Page 1: Dan Cooperberg Alternate technology ABB Lummus … To Gasoline Pool Kero/Jet Diesel Oil C 3’s To Gasoline Pool MTBE Crude Unit Stabilizer CAT - Cracker Complex Vacuum Unit Fuel Oil

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Alternate technologyoptions forprocessing refineryresidues

Dan CooperbergABB Lummus Global

Gasification TechnologyConference

October 8, 2001

Page 2: Dan Cooperberg Alternate technology ABB Lummus … To Gasoline Pool Kero/Jet Diesel Oil C 3’s To Gasoline Pool MTBE Crude Unit Stabilizer CAT - Cracker Complex Vacuum Unit Fuel Oil

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Refinery product trends

Need to produce cleaner productsGasoline – Euro 3/Euro 4 specificationsDiesel – Euro 3/Euro 4 specificationsRefinery fuel – Lower sulfur

Significant reduction in high sulfur fuel oil demandReduce HSFO productionSubstitute LSFO for HSFO

Limited availability of low sulfur light crudesResult:

Investment in refinery residue processing needed

Page 3: Dan Cooperberg Alternate technology ABB Lummus … To Gasoline Pool Kero/Jet Diesel Oil C 3’s To Gasoline Pool MTBE Crude Unit Stabilizer CAT - Cracker Complex Vacuum Unit Fuel Oil

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Crude Oil

VacResid

VIS.DS LGO

VBResid

LPG

To Gasoline Pool

Kero/Jet

Diesel OilC3’s

To Gasoline Pool

MTBE

CrudeUnit

Stabilizer

CAT - CrackerComplex

VacuumUnit

Fuel Oil

(A) Euro IV Quality AsphaltAsphalt

Kerosine

Gas Plant

Reformer

AlkylationiC4

Alkylate

DS LGO

N-HDS

K-HDS

LT. G.O. D-HDS (A)

H2 Rich Gas

LCOHCOto

D-HDS

MTBE

Gas Plant

MethanolC4’s

Lt. Naphtha to Gasoline

VBLGO

Figure 1 - Base case refinery

HDSVGO Pretreater

Page 4: Dan Cooperberg Alternate technology ABB Lummus … To Gasoline Pool Kero/Jet Diesel Oil C 3’s To Gasoline Pool MTBE Crude Unit Stabilizer CAT - Cracker Complex Vacuum Unit Fuel Oil

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Option BASE Crude Type Arab Light

UNITS (kBPSD) (a)

Crude Unit 150Vacuum Unit 65Naphtha HDS 38Distillate HDS 33Cat. Reformer (b) 26Cat Cracker(FCCU) 44Visbreaker 20 VGO HDT 44Gasoline HDT 30

(a) Typical Refinery has capacities as shown based on AL design basis(b) Merox Units, as well as Isomerization, MTBE and alkylation Units are also included

Base case unit capacities(150,000 bpsd or 20,000 mt/d )

Page 5: Dan Cooperberg Alternate technology ABB Lummus … To Gasoline Pool Kero/Jet Diesel Oil C 3’s To Gasoline Pool MTBE Crude Unit Stabilizer CAT - Cracker Complex Vacuum Unit Fuel Oil

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Factors to considerResidue upgrading options

Existing refinery configurationCapacityCrude slateDegree of residue conversionDegree of VGO hydrotreating ( or hydroconversion )

Current product qualityGasolineDiesel

Future product specificationsFuture product requirements

Outlet for H.S.F.O.Need for powerExpansion requirements

Page 6: Dan Cooperberg Alternate technology ABB Lummus … To Gasoline Pool Kero/Jet Diesel Oil C 3’s To Gasoline Pool MTBE Crude Unit Stabilizer CAT - Cracker Complex Vacuum Unit Fuel Oil

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Key assumptions Producing EU clean products in 2005

Year Current 2005Gasoline Specifications

Unleaded Pool (Ron/Mon) 95/85 95/85Sulfur Spec, max. ppm 150 50Aromatics, vol. % max. 35 35Olefins, wt.% max. 18

Diesel SpecificationsSulfur, ppm. max. 350 50Cetane Index, min. 51 51Specific Gravity, max. 0.845

Fuel Oil ProductionDecrease H.S. Fuel Oil ProductFuel Oil Product, %S max. 1.0

Page 7: Dan Cooperberg Alternate technology ABB Lummus … To Gasoline Pool Kero/Jet Diesel Oil C 3’s To Gasoline Pool MTBE Crude Unit Stabilizer CAT - Cracker Complex Vacuum Unit Fuel Oil

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Option Base

Crude Type AL VGO Hydrodesulfurization Yes

Production ( MT/D) (a) C3 LPG/C3 Mix 570Gasoline (95/85) 8340Kero/Jet 2060LS Diesel 4300HSFO 3750Product QualityGasoline (ppm-s) 18Diesel (ppm-s) 36Diesel Cetane Number 56HFO (wt%S) 3.3

(a) Excludes 100 K-MTA of Bitumen

Base refinery operations - 20,000 mt/d( Minimal vacuum resid processing )

Page 8: Dan Cooperberg Alternate technology ABB Lummus … To Gasoline Pool Kero/Jet Diesel Oil C 3’s To Gasoline Pool MTBE Crude Unit Stabilizer CAT - Cracker Complex Vacuum Unit Fuel Oil

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Potential refinery options to evaluate

Define existing refinery configurationIdentify possible residue upgrading optionsIdentify potential crude availability ( e.g. in Europe )

Mid East blendsRussian crudes and feedstockslow sulfur ( North Sea , Africa )

Impact of crude and product pricing differentialsImpact of future power pricingImpact of financing conditions

Page 9: Dan Cooperberg Alternate technology ABB Lummus … To Gasoline Pool Kero/Jet Diesel Oil C 3’s To Gasoline Pool MTBE Crude Unit Stabilizer CAT - Cracker Complex Vacuum Unit Fuel Oil

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Option Configuration Residue Products

Base(a) Typical Existing Refinery 3.5%S Fuel Oil

1 LC-FiningSM unit @ 65% Conversion 1.0%S Fuel Oil

2 Delayed Coker 6%S Fuel Coke

3 Delayed Coker & POX 200 MW Power (b)

4 Deasphalting & POX 500 MW Power (b)

5 Visbreaking/Vac Flash/POX 630 MW Power (b)

(a) Uses Arab Light with VGO hydrotreating

(b) Includes hydrogen generation, Net Power Output includes refinery requirements

Basis: 150,000 bbl/d crude feedResidue upgrading comparison

Page 10: Dan Cooperberg Alternate technology ABB Lummus … To Gasoline Pool Kero/Jet Diesel Oil C 3’s To Gasoline Pool MTBE Crude Unit Stabilizer CAT - Cracker Complex Vacuum Unit Fuel Oil

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Residue processing options to consider (part 1)

Add LC-Fining unitEliminates production of HSFOCan be used to process wide variety of crudesOffers product slate flexibility

Add delayed coker complexComplete conversion of vacuum residuerequires coke dispositionrequires gas oil hydroconversion treatment

Add coke based IGCC for power / steam generation

Page 11: Dan Cooperberg Alternate technology ABB Lummus … To Gasoline Pool Kero/Jet Diesel Oil C 3’s To Gasoline Pool MTBE Crude Unit Stabilizer CAT - Cracker Complex Vacuum Unit Fuel Oil

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Residue processing options to consider (part 2)

Increase visbreaker conversion & install IGCCAdd vac.flasher or VF with added heaterEliminates production of HFOrequires ability to sell excess powerIGCC can be built and owned by others

Add SDA unit & install IGCC unitEliminates production of HFOrequires ability to sell excess powerIGCC can be built and owned by others

Install hydrocrackerSuitable for processing thermal and conversion gas oilsOffers good crude flexibility

Page 12: Dan Cooperberg Alternate technology ABB Lummus … To Gasoline Pool Kero/Jet Diesel Oil C 3’s To Gasoline Pool MTBE Crude Unit Stabilizer CAT - Cracker Complex Vacuum Unit Fuel Oil

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Option 1 - LC-Fining upgrading

Vacuum Unit VGO HDS

HydrogenPlant

D-HDSUnit

FCCU

AsphaltPlant

LC-Fining65%

Conversion

Atmos.Resid

VacuumResid

Asphalt

1% S Fuel Oil

DSGas Oil

HydrogenNatural

Fuel Gas

VGO

VGOHCO (A)

Distillate

HDS LCO

LCO

Resid

To Naphtha

(A)

(A) Diluent

New

Revamped

Page 13: Dan Cooperberg Alternate technology ABB Lummus … To Gasoline Pool Kero/Jet Diesel Oil C 3’s To Gasoline Pool MTBE Crude Unit Stabilizer CAT - Cracker Complex Vacuum Unit Fuel Oil

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Option 2 - Delayed coking

VGO/HCGOFHC

HydrogenPlant

LCO/LGOHDT

FCCU

AsphaltPlant

DelayedCoking

VGO

Atmos.Resid

VacuumResid

Asphalt

Fuel Coke to Sale

DSGas Oil

HydrogenFuel Gas

VGO

HCGO

Light Naphtha to FCC

LCGO

Heavy Naphtha

LCO

HCO toRefinery Fuelor Sales

HCGO To VGO/HCGOMHC

VGOHDS

Vacuum Unit

New

Revamped

Page 14: Dan Cooperberg Alternate technology ABB Lummus … To Gasoline Pool Kero/Jet Diesel Oil C 3’s To Gasoline Pool MTBE Crude Unit Stabilizer CAT - Cracker Complex Vacuum Unit Fuel Oil

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VGO/HGOFHC

LCO/LGOHDT

FCCU

AsphaltPlant

DelayedCoking

LVGO

Atmos.Resid

VacuumResid

Asphalt

H2S to SulfurRecovery

DSGas Oil

HVGO

LGO

Heavy Naphtha

LCO

HCO toRefinery Fuelor Sales

Gasification& Acid Gas

Removal

HydrogenRecovery

Cogeneration& Power Gen

FuelGas

Hydrogen

Steam

Power

MediumBTU Gas

Coke

Option 3 - Delayed coking + IGCC

VGOHDS

HCGO

To VGO/HCGO MHC

LN to FCC

Vacuum Unit

New

Revamped

Page 15: Dan Cooperberg Alternate technology ABB Lummus … To Gasoline Pool Kero/Jet Diesel Oil C 3’s To Gasoline Pool MTBE Crude Unit Stabilizer CAT - Cracker Complex Vacuum Unit Fuel Oil

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VGO/DAOFHC

D - HDS

FCCU

AsphaltPlant

Deasphalting~50% Lift

VGO

Atmos.Resid

VacuumResid

Asphalt

H2S to SulfurRecovery

DSGas Oil

VGO

DAO

LCO

HCO toRefinery Fuelor Sales

Gasification& Acid Gas

Removal

Hydrogen Recovery

Cogeneration& Power Gen

FuelGas

Hydrogen

Steam

Power

MediumBTU Gas

Pitch

Option 4 - Deasphalting + IGCC

VGOHDS

Refinery Fuelor Sales

Vacuum Unit

New

Revamped

Page 16: Dan Cooperberg Alternate technology ABB Lummus … To Gasoline Pool Kero/Jet Diesel Oil C 3’s To Gasoline Pool MTBE Crude Unit Stabilizer CAT - Cracker Complex Vacuum Unit Fuel Oil

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VGOHDS

D - HDS

FCCU

AsphaltPlant

VGO

Atoms.Resid

VacuumResid

Asphalt

H2S to SulfurRecovery

DSGas Oil

VGO

Naphtha to FCC

VB VGO

LCO

HCO toRefinery Fuelor Sales

Gasification& Acid Gas

Removal

Hydrogen Recovery

Cogeneration& Power Gen

FuelGas

Hydrogen

Steam

Power

MediumBTU Gas

Tar

Option 5 - Visbreaking/vacuum flasher + IGCC

Visbreakingwith Vacuum

FlasherAdded

VB VGO

VBGO

Vacuum Unit

New

Revamped

Page 17: Dan Cooperberg Alternate technology ABB Lummus … To Gasoline Pool Kero/Jet Diesel Oil C 3’s To Gasoline Pool MTBE Crude Unit Stabilizer CAT - Cracker Complex Vacuum Unit Fuel Oil

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Residue processing options

NaphthaInject into FCCU riserProcess in naphtha HDS (>50 bar)

Light gas oilNeeds hydrotreating (~75 bar) to saturate aromatics

Heavy gas oilNeeds to hydrotreat (>75 bar) or hydrocrack

CokeSalePower generation via IGCC

(Coker effluent processing )

Page 18: Dan Cooperberg Alternate technology ABB Lummus … To Gasoline Pool Kero/Jet Diesel Oil C 3’s To Gasoline Pool MTBE Crude Unit Stabilizer CAT - Cracker Complex Vacuum Unit Fuel Oil

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Residue processing options

NaphthaInject into FCCU riserProcess in naphtha HDS (>50 bar)

Light gas oilNeeds hydrotreating (~75 bar) to saturate aromatics

Heavy gas oilNeeds to hydrotreat (>75 bar) or hydrocrack

TarPower generation

(Visbreaking/vacuum flash effluent processing )

Page 19: Dan Cooperberg Alternate technology ABB Lummus … To Gasoline Pool Kero/Jet Diesel Oil C 3’s To Gasoline Pool MTBE Crude Unit Stabilizer CAT - Cracker Complex Vacuum Unit Fuel Oil

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Material balance comparison (20,000 mt/d )

MATERIAL BALANCE COMPARISON

( MT / D )

Option Base 1 2 3 4 5

DESCRIPTION Base LCFINER Delayed Coker + SDA + VB with FlasherCase (65 %) Coker IGCC IGCC & IGCC

Crude Split 100/0 0/100 0/100 0/100 0/100 0/100Long Resid Import ( 25,000 b/d) Y Y YProduction MT/D

C3 LPG 143 174 201 201 185 166Propane/Propylene Mix 426 476 394 394 450 49695/85 Gasoline 8,343 8,542 8,683 8,683 8,453 8,542Kero/Jet 2,061 1,711 1,466 1,466 1,567 1,567LS Diesel 4,295 4,405 9,260 9,292 8,298 4,402#2 Heating Oil 0 711 393 435 394 8103.5% S Fuel Oil 3,751 0 0 0 0 01.0% S Fuel Oil 0 3,473 0 0 0 0Asphalt Plant Feed 290 290 290 290 290 290coke 0 0 2,345 0 0 0sulfur 214 520 521 678 674 538

Total liquid/Solid Product 19,522 20,302 23,553 21,439 20,310 16,811

Power Import, MW (a) 37,724 49,973 50,004 -195,335 -498,367 -633,637

Page 20: Dan Cooperberg Alternate technology ABB Lummus … To Gasoline Pool Kero/Jet Diesel Oil C 3’s To Gasoline Pool MTBE Crude Unit Stabilizer CAT - Cracker Complex Vacuum Unit Fuel Oil

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(Includes 30% allowance for offsites)Investment costs $MM - Basis: N.W. Europe 2001

Delta InvestmentOption Configuration MM $

Base Base Refinery with Visbreaker Existing Facility

1 LC Finer @ 65% Conversion 361

2 a Delayed Coker 456

3 a Delayed Coker with IGCC 743

4 a Solvent Deasphalting & Gasification (IGCC) 865

5 Visbreaking with Vac. Flasher and Gasification (IGCC) 759

Note: a) Includes processing of 25,000 bpsd of long residue

Page 21: Dan Cooperberg Alternate technology ABB Lummus … To Gasoline Pool Kero/Jet Diesel Oil C 3’s To Gasoline Pool MTBE Crude Unit Stabilizer CAT - Cracker Complex Vacuum Unit Fuel Oil

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Prices used in study5 Year Average 1995 - 1999 @ Rotterdam

FEEDS $ / MT

Arabian Light 125.42$ Arabian Heavy 112.00$ Natural Gas 125.00$ n-Butane 265.20$ MTBE 271.50$ Methanol 160.00$

PRODUCTS $ / MT

C3 LPG 167.00$ Propane/Propylene Mix 260.00$ C4 LPG 160.00$ 95/85 Regular Unleaded 184.67$ Jet / Kerosene 180.51$ L.S. Diesel 165.88$ Gas Oil ( No. 2 Fuel Oil ) 160.64$ L.S. Fuel Oil ( 1 - 1.4 % ) 99.50$ H.S. Fuel Oil ( 3.5 % max. ) 90.60$ H.S. Fuel Coke 10.00$ Carbon Black Feed 104.50$ Bitumen Feed 88.00$ Sulfur 65.00$

Power 35$ - 50$ / MW-Hr

Page 22: Dan Cooperberg Alternate technology ABB Lummus … To Gasoline Pool Kero/Jet Diesel Oil C 3’s To Gasoline Pool MTBE Crude Unit Stabilizer CAT - Cracker Complex Vacuum Unit Fuel Oil

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Cash flow calculations

Project life 20 yearsDepreciation 10 years (straight line)Interest (a) 7% per yearDebt/equity 75/25Loan payback 7 years + 3 years grace periodTax rate 35%Salvage value 10% of original cost

Product/crude pricing 5 year average (1995-1999)(b)(a) Base rate + premium and swap fees(b) Rotterdam location

Page 23: Dan Cooperberg Alternate technology ABB Lummus … To Gasoline Pool Kero/Jet Diesel Oil C 3’s To Gasoline Pool MTBE Crude Unit Stabilizer CAT - Cracker Complex Vacuum Unit Fuel Oil

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Study - 1A: IRR vs power tariff (1995-1999 Prices )

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5101520253035

$35 $40 $45 $50 $55Power Tariff ( $/MWH )

IRR

( % )

LC-Fining Coker Coker/IGCC

��������������������

�������������������� SDA/IGCC Vis./VF/IGCC

Debt/equity @ 75/25

Page 24: Dan Cooperberg Alternate technology ABB Lummus … To Gasoline Pool Kero/Jet Diesel Oil C 3’s To Gasoline Pool MTBE Crude Unit Stabilizer CAT - Cracker Complex Vacuum Unit Fuel Oil

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Prices used in study2.5 Year Average 1999 - 2001 @ Rotterdam

FEEDS $ / MT

Arabian Light 165.40$ Arabian Heavy 151.60$ Natural Gas 151.00$ n-Butane 265.20$ MTBE 381.00$ Methanol 160.00$

PRODUCTS $ / MT

C3 LPG 240.00$ Propane/Propylene Mix 380.00$ C4 LPG 233.00$ 95/85 Regular Unleaded 275.00$ Jet / Kerosene 272.50$ L.S. Diesel 255.00$ Gas Oil ( No. 2 Fuel Oil ) 234.00$ L.S. Fuel Oil ( 1 - 1.4 % ) 138.60$ H.S. Fuel Oil ( 3.5 % max. ) 126.00$ H.S. Fuel Coke 10.00$ Carbon Black Feed 143.60$ Bitumen Feed 123.40$ Sulfur 65.00$

Power 35$ - 50$ / MW-Hr

Page 25: Dan Cooperberg Alternate technology ABB Lummus … To Gasoline Pool Kero/Jet Diesel Oil C 3’s To Gasoline Pool MTBE Crude Unit Stabilizer CAT - Cracker Complex Vacuum Unit Fuel Oil

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05

10152025303540

$35 $40 $45 $50 $55Power Tariff ( $/MWH )

IRR

( %

)

LC Fining Coking Coker/IGCC

���������������������� SDA/IGCC Vis./VF/IGCC

Study - 1b: IRR vs power tariff (1999-2001 Prices )Debt/equity @ 75/25

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14

16

18

20

22

24

26

$35 $40 $45 50 55Power Tariff ( $/MWH )

IRR

( % )

Coke(10/mt)

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coke(20/mt) Coke (30/mt) Coker/IGCC

Study - 1c: IRR vs power tariff (Coke price sensitivity)Debt/equity @ 75/25

Page 27: Dan Cooperberg Alternate technology ABB Lummus … To Gasoline Pool Kero/Jet Diesel Oil C 3’s To Gasoline Pool MTBE Crude Unit Stabilizer CAT - Cracker Complex Vacuum Unit Fuel Oil

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General conclusions

Elimination of H.S. F.O. will require significant refineryinvestment.Thermal upgrading processes will require addition of VGOHydroconversionWith addition of residue conversion processes refinersshould examine viability of long residue import

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General conclusions (part 2)

IGCC options competitive with non IGCC options.IGCC options more competitive when refinery grossmargins are low. ( 1995 -1999 price basis )Power co-production, provides a more stable clean productrevenue stream.If refineries have existing hydrocracker units, thermalprocessing options with power generation will haveimproved rates of returnIGCC projects allow refiners to explore added financingoptions with potential investors in the IGCC unit or residueconversion facilities